Cut-out sintered ceramic sheet and method of manufacturing the same

Abstract

A method of manufacturing a cut-out sintered ceramic sheet including forming a ceramic green sheet, sintering the formed ceramic green sheet, adhering a plastic resin film onto which adhesive is applied on at least one surface of the sintered ceramic sheet, and shearing the sintered ceramic sheet.

What is claimed is: 
     
       1. A method of manufacturing a cut-out sintered ceramic sheet, comprising the steps of:
 providing a sintered ceramic sheet having a plastic film adhered to at least one surface thereof; and 
 shearing the sintered ceramic sheet by linearly displacing edges of an upper and lower die to form a sheared sintered ceramic sheet; wherein: 
 the edge of the upper die and the edge of the lower die are (i) spaced apart to have a clearance between the edges of the upper and lower die while shearing the sintered ceramic sheet and (ii) offset such that the upper and lower dies do not directly contact a resulting surface of a fracture site. 
 
     
     
       2. The method of  claim 1 , wherein the plastic film extends to an end portion of a sheared edge of the sintered ceramic sheet. 
     
     
       3. The method of  claim 1 , wherein the clearance between the edges of the upper and lower dies is from 5 μm to 50 μm. 
     
     
       4. The method of  claim 3 , wherein the sintered ceramic sheet is sandwiched between the upper die and a second pressing module in a lower side of the upper die, and sandwiched and fixed by the lower die juxtaposed on the second pressing module and a first pressing module opposite in an upper side of the lower die, wherein the upper and lower dies are relatively displaced with a predetermined load. 
     
     
       5. The method of  claim 1 , wherein the sintered ceramic sheet is sheared to separate the sintered ceramic sheet into an inner area and an outer area surrounding the inner area. 
     
     
       6. The method of  claim 1 , wherein the sintered ceramic sheet is sheared to separate the sintered ceramic sheet into an inner area, an annular area surrounding the inner area, and an outer area surrounding the annular area. 
     
     
       7. The method of  claim 1 , wherein the sintered ceramic sheet is manufactured according to the method including the steps of:
 forming a ceramic green sheet; 
 sintering the formed ceramic green sheet; and 
 adhering the plastic film to at least one surface of the sintered ceramic sheet. 
 
     
     
       8. A cut-out sintered ceramic sheet manufactured according to the method of  claim 1 . 
     
     
       9. A method of manufacturing a cut-out sintered ceramic sheet, comprising the steps of:
 forming a ceramic green sheet; 
 sintering the formed ceramic green sheet; 
 adhering a plastic resin film onto which adhesive is applied on at least one surface of the sintered ceramic sheet; and 
 shearing the sintered ceramic sheet by linearly displacing edges of an upper and lower die to form a sheared sintered ceramic sheet; wherein: 
 the edge of the upper die and the edge of the lower die are (i) spaced apart to have a clearance between the edges of the upper and lower die while shearing the sintered ceramic sheet and (ii) offset such that the upper and lower dies do not directly contact a resulting surface of a fracture site. 
 
     
     
       10. The method of  claim 1 , in which the shearing step includes directly or indirectly pressing the sintered ceramic sheet having the film adhered thereto by a first or second pressing module against contacting surfaces of upper and lower dies and shearing the same between edges provided on the contacting surfaces of the upper and lower dies. 
     
     
       11. The method of  claim 9 , wherein the clearance between the edges of the upper and lower dies is from 5 μm to 50 μm. 
     
     
       12. The method of  claim 1 , wherein the ceramic sintered sheet comprises at least one of alumina, zirconia, titanium, silica, aluminum nitride, silicon nitride, silicon carbide, cordierite, or mullite. 
     
     
       13. The method of  claim 9 , wherein the ceramic sintered sheet comprises at least one of alumina, zirconia, titanium, silica, aluminum nitride, silicon nitride, silicon carbide, cordierite, or mullite. 
     
     
       14. The method of  claim 1 , wherein the sheared sintered ceramic sheet is substantially free of burrs along the resulting surface of the fracture site of the sheared sintered ceramic sheet. 
     
     
       15. The method of  claim 3 , wherein the sheared sintered ceramic sheet is substantially free of burrs along the resulting surface of the fracture site of the sheared sintered ceramic sheet. 
     
     
       16. The method of  claim 11 , wherein the sheared sintered ceramic sheet is substantially free of burrs along the resulting surface of the fracture site of the sheared sintered ceramic sheet.